Detailed Project Report on TUK TUK E-RICKSHAW (CAP: 40 NOS/DAY)

Electric rickshaws (also known as Tuk Tuk, e-rickshaw) have been becoming more popular in some cities since 2008 as an alternative to auto rickshaws and pulled rickshaw because of their low fuel cost, and less human effort compared to pulled rickshaws. They are being widely accepted as an alternative to Petrol/Diesel/CNG auto rickshaws. They are 3 wheels pulled by an electric motor ranging from 650-1400 Watts. They are mostly manufactured in China, only a few other countries manufacture these vehicles.

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ENGINEERS INDIA RESEARCH INSTITUTE
4/54, Roop Nagar, Delhi-110007 (India)
Phone: [phone]
E-mail: [email protected]
Website: www.eiriindia.org



TUK TUK E-RICKSHAW (CAP: 40 NOS/DAY)
[EIRI/EDPR/4727] J.C.: 2947US$

Electric rickshaws (also known as Tuk Tuk, e-rickshaw) have been becoming more
popular in some cities since 2008 as an alternative to auto rickshaws and pulled
rickshaw because of their low fuel cost, and less human effort compared to pulled
rickshaws. They are being widely accepted as an alternative to Petrol/Diesel/CNG
auto rickshaws. They are 3 wheels pulled by an electric motor ranging from 650-
1400 Watts. They are mostly manufactured in China, only a few other countries
manufacture these vehicles.

Battery-run rickshaws could be a low- emitter complementary transport for the
low-income people, who suffer most from a lack of transport facility, if introduced
in a systematic manner according to experts.

E-rickshaws are compact but very useful vehicles, with three wheels and use
electric power from batteries to run. They use an electric motor as power source
which draws electric power from the rechargeable batteries installed in the
rickshaw body. These battery operated vehicles are perfect for small distant
transport. Both for the cargo and people, they are perfect for running on narrow
streets because of their small size. But the biggest reason for their popularity is
low operating cost and zero pollution emission. They are powered by electric
motors instead of petrol or diesel motors which make it best for pollution free,
environmental friendly transport systems in short distances.

Actually they are not capable of running long distances. E-rickshaws are now one
of the preferred modes of transport in streets because of its low maintenance cost,
low fuel cost eco-friendly. To noise pollution, easy to drive and last but not the
least livelihood, e-rickshaw is a boon to the common Man.Without putting in
much physical effort and without investing much money, the earning is quite good
for an e-rickshaw driver and hence it is an important means of livelihood for
many.

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These e-rickshaws consist of 3 wheels with a differential mechanism at rear
wheels. Basically these vehicles have a mild steel tubular chassis. The motor is
brushless DC motor manufactured mostly in India and China. The electrical
system used in Indian version is 48V DC and can run 90 -100 km/full charge.
Basic seating capacity is driver plus 4 passengers. These vehicles are now started
using in transporting light weight goods as e- loader. Hence there are lots of
opportunities of income.

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CONTENTS

INTRODUCTION

MACHINERY USED: -

USES AND APPLICATIONS

WORKING PRINCIPLE

MAJOR PARTS AND COMPONENTS

ENVIRONMENTAL ASPECTS

E-RICKSHAW SERVICES

DRAWBACKS OF PRESENT SCENARIO

FUTURE SCOPE

MARKET SURVEY

BEST E - RICKSHAW MANUFACTURERS IN INDIA

1. MAHINDRA ELECTRIC

2. JANRATH E RICKSHAW

3. ATUL AUTO

4. PIAGGIO VEHICLES

5. KINETIC GREEN

6. THUKRAL ELECTRIC

7. UDAAN

8. MAYURI

9. MINI METRO EV

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10. CITY LIFE

PRESENT E-RICKSHAW SERVICES

THE SOCIO-ECONOMIC ASPECT INTO CONSIDERATION

BATTERY OPERATED E RICKSHAW IN DELHI

FEATURES AND SPECIFICATION OF E- RICKSHAW

FEATURES:

SPECIFICATIONS:

PRESENT MANUFACTURERS OF ICAT APPROVES E-RICKSHAW

GOVT LEGISLATIVE AND POLICY FOR E -RICKSHAW

STATEMENT OF ISSUE

FOLLOWING ISSUES NEED TO BE ADDRESSED THROUGH AN E-RICKSHAW
POLICY:

CPPR AND E-RICKSHAWS

SUBSIDIES AND DETAILS OF GOVT APPROVAL FOR E-RICKSHAW

SCENARIO OF E-RICKSHAW

FIGURE: PREVIOUS PROFESSIONS OF THE BATTERY RICKSHAW DRIVERS

TABLE: EDUCATIONAL QUALIFICATIONS OF DRIVERS

E-RICKSHAW SPECIFICATION

SPECIFICATION OF E-LOADER IN HOSPITALITY SECTOR

DESIGN AND CONSTRUCTION OF E-RICKSHAWS

BATTERY:

ELECTRIC MOTOR:

CONTROLLER:

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REGENERATIVE BRAKING:

CHARGING SYSTEM:

CONTROLS AND INSTRUMENTATION:

DESIGN AND CONSTRUCTION OF E-RICKSHAW (ELECTRIC TUK- TUKS)

CHASSIS:

WHEELS AND DIFFERENTIAL MECHANISM:

MOTOR:

ELECTRICAL SYSTEM:

BODY DESIGN:

BATTERIES:

MANUFACTURING PROCESS OF E-RICKSHAW

SUB-ASSEMBLIES ARE: -

AUTO CAD DESIGNING

RESEARCH & DEVELOPMENT (R&D)

STORING & GO DOWN

FABRICATION

SAND BLASTING & POWDER COATING

ASSEMBLING FITTING & WIRING

TESTING & CHECKING

DELIVERY & FORWARDING

PROCESS OF MANUFACTURING THROUGH FLOW SHEET

ADVANTAGES OF E -RICKSHAW

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E-RICKSHAW MANUFACTURING

E-RICKSHAW MANUFACTURING PROCESS

E-RICKSHAW MANUFACTURING PROCESS INVOLVES FIVE CORE STEPS. THEY
ARE:

1. STAMPING E-RICKSHAW BODY PARTS

THE STAMPING PROCESS CAN BE DIVIDED INTO TWO MAJOR TYPES:
SEPARATION PROCESS AND FORMING PROCESS. HERE’S A CLOSER LOOK AT
THE STAMPING PROCESS:

2. WELDING E-RICKSHAW BODY PARTS

3. PAINTING E-RICKSHAW BODY PARTS

WHY IS PAINTING THE E-RICKSHAW BODY NECESSARY

4. E-RICKSHAW ASSEMBLING

• E-RICKSHAW CHASSIS ASSEMBLY:

• E-RICKSHAW BODY ASSEMBLY:

• TRIM ASSEMBLY:

5. E-RICKSHAW TESTING AND ADJUSTMENT

SAFETY REQUIREMENT OF TRACTION BATTERIES FOR BATTERY OPERATED
VEHICLE

SCOPE

1. REFERENCES

2. REQUIREMENTS

2.1.1.2 REQUIREMENTS

2.1.2 OVERCHARGE TEST (CELL LEVEL OR BATTERY MODULE OR BATTERY
PACK)

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2.1.2.1 PROCEDURE FOR OVERCHARGE TEST

2.1.2.2 REQUIREMENTS

2.2 MECHANICAL TESTS

2.2.1 VIBRATION TEST

2.2.1.1 TEST DESCRIPTION

2.2.1.2 REQUIREMENTS

2.2.2 SHOCK TEST

2.2.2.1 TEST DESCRIPTION

2.2.2.2 REQUIREMENTS

2.2.3.1 TEST DESCRIPTION

2.2.3.2 REQUIREMENTS

2.2.4 PENETRATION TEST (CELL LEVEL OR BATTERY MODULE)

2.2.4.1 TEST DESCRIPTION

2.2.4.2 TEST SPECIFICATIONS

2.2.4.3 REQUIREMENTS

3.0 BATTERY PARAMETERS

4 APPLICATION FOR APPROVAL

5.0 CHANGES IN TECHNICAL SPECIFICATION

5.5. CRITERIA FOR EXTENSION OF APPROVAL

6.0 CONFORMITY OF PRODUCTION (COP)

ANNEXURE - A

A-1 RATED CAPACITY

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A-1.1 TEST FOR CAPACITY

WORKING OPERATED OF E-RICKSHAWS

DOCUMENTS REQUIRED FOR REGISTRATION OF AN E-RICKSHAW

(L) FOR NEW E-RIC KSHAW

(LL) CERTTFTCATE OF FTTNESS

(LLL) DOCUMENTS REQUIRED-FOR ISSUANCE OF PERMIT TO E-RICKSHAW

ORDINANCE PROMULGATED FOR GIVING RELIEF TO DRIVERS OF E-
RICKSHAWS AND E -CARTS

REASONS TO BUY E RICKSHAW

COST-EFFECTIVENESS:

ENVIRONMENTAL SUSTAINABILITY:

ENERGY EFFICIENCY:

GOVERNMENT INCENTIVES AND SUPPORT:

GROWING DEMAND AND MARKET POTENTIAL:

IMPROVED PERFORMANCE AND SAFETY:

SOCIAL IMPACT AND EMPLOYMENT OPPORTUNITIES:

CONSULTANT FOR E-RICKSHAW

ICAT (INTERNATIONAL CENTRE FOR AUTOMOTIVE TECHNOLOGY

SUPPLIERS OF PLANT & MACHINERY

POWER PRESS

POWER SHEARING MACHINE

HYDRAULIC PRESS

BENDING MACHINE

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WELDING EQUIPMENTS

TESTING EQUIPMENT AND MACHINES

STAILESS STELL PIPE MANUFACTURE/SUPPLIERS

GENERATOR SET MANUFACTURER

POWDER COATING MACHINE

MATERIAL HANDLING EQUIPMENTS

SUPPLIERS OF RAW MATERIALS

CHASIS

TRACTION BATTERY

STEEL PIPE

PICKLING CHEMICALS

LABORATORY TESTING EQUIPMENTS

SUPPLIERS OF METAL TESTING MACHINE

SUPPLIERS OF DRILLING, LATHE, TAPING MACHINES

SUPPLIERS OF EOT CRANE

SUPPLIERS OF POWER TRANSFORMERS

SUPPLIERS OF ELECTRICAL PANEL

SUPPLIERS OF ELECTRIC MOTOR

SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS

SUPPLIERS OF PLATFORM WEIGHING MACHINE

SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS

SUPPLIERS OF FIRE FIGHTING EQUIPMENTS

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SUPPLIERS OF JIGS AND FIXTURE

PRINCIPLES OF PLANT LAYOUT

MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:

PLANT LOCATION FACTORS

PRIMARY FACTORS

1. RAW-MATERIAL SUPPLY:

2. MARKETS:

3. POWER AND FUEL SUPPLY:

4. WATER SUPPLY:

5. CLIMATE:

SPECIFIC FACTORS

6. TRANSPORTATION:

A. AVAILABILITY OF VARIOUS SERVICES AND PROJECTED RATES

7. WASTE DISPOSAL:

8. LABOR:

9. REGULATORY LAWS:

10. TAXES:

11. SITE CHARACTERISTICS:

12. COMMUNITY FACTORS:

13. VULNERABILITY TO WARTIME ATTACK:

14. FLOOD AND FIRE CONTROL:

EXPLANATION OF TERMS USED IN THE PROJECT REPORT

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1. DEPRECIATION:

2. FIXED ASSETS:

3. WORKING CAPITAL:

4. BREAK-EVEN POINT:

5. OTHER FIXED EXPENSES:

6. MARGIN MONEY:

7. TOTAL LOAD:

8. LAND AREA/MAN POWER RATIO:

PROJECT IMPLEMENTATION SCHEDULES

INTRODUCTION

PROJECT HANDLING

PROJECT SCHEDULING

PROJECT CONSTRUCTION SCHEDULE

TIME SCHEDULE

GENERATION AND MANAGEMENT OF WASTES

SOLID WASTES

LIQUID WASTES

GASEOUS EMISSION

OTHERS

INDUSTRIAL WASTE MANAGEMENT

SEWERAGE SYSTEM

ANTICIPATED ENVIRONMENTAL IMPACTS

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CONSTRUCTION PHASE

OPERATION PHASE

MITIGATION MEASURES (PROPOSED)

HEALTH SAFETY & ENVIRONMENT

SAFETY & OCCUPATIONAL MEASURE (STORAGE/HANDLING OF RAW
MATERIAL & PRODUCT)

SAFETY DATA SHEETS

ENVIRONMENTAL/SAFETY LIABIL ITY

PRE-PROJECT ACTIVITIES

PROPOSED IMPLEMENTATION SCHEDULE

PLANT LAYOUT

STATUTORY APPROVALS FROM GOVERNMENT

DOCUMENTS REQUIRED FOR LICENSES

LIST OF DOCUMENTS:

SWOL ANALYSIS

STRENGTHS

OPPORTUNITIES

WEAKNESS

LIMITATIONS

ORGANIZATION CHART

IMPLEMENTATION SCHEDULE

E-RICKSHAW PARTS DETAILS

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PROJECT LOCATION COUNTRY

ADDIS ABABA


APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING

03. PLANT AND MACHINERY

04. OTHER FIXED ASSESTS

05. FIXED CAPITAL

06. RAW MATERIAL

07. SALARY AND WAGES

08. UTILITIES AND OVERHEADS

09. TOTAL WORKING CAPITAL

10. TOTAL CAPITAL INVESTMENT

11. COST OF PRODUCTION

12. TURN OVER/ANNUM

13. BREAK EVEN POINT

14. RESOURCES FOR FINANCE

15. INSTALMENT PAYABLE IN 5 YEARS

16. DEPRECIATION CHART FOR 5 YEARS

17. PROFIT ANALYSIS FOR 5 YEARS

18. PROJECTED BALANCE SHEET FOR (5 YEARS)

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COST ESTIMATION

Plant Capacity 40 Nos/Day

Land & Building (12,000 sq.mt.) US$ 6.67 Lac

Plant & Machinery US$ 8.15 Lac

Working Capital for 3 Months US$ 66.55 Lac

Total Capital Investment US$ 82.17 Lac

Rate of Return 27%

Break Even Point 47%